Moisture management support garment with a denier differential mechanism

ABSTRACT

A moisture management fabric using denier differential to facilitate the movement of sweat away from the wearer&#39;s body is presented. An exemplary moisture management support garment constructed from an exemplary moisture management fabric is presented. An exemplary moisture management support garment is a moisture transporting sport bra. A denier differential is employed to provide superior moisture transporting and evaporation of perspiration from a wearer during exertion. The denier differential relies upon a facing layer and a back layer with substantially different yarn thickness and fabric porosity to achieve fluid transport.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application, having U.S. application Ser. No. 16/674,822, filedNov. 5, 2019, entitled “Moisture Management Support Garment with aDenier Differential Mechanism,” is a Divisional Application of U.S.application Ser. No. 15/495,209, filed Apr. 24, 2017, entitled “MoistureManagement Support Garment With A Denier Differential Mechanism” andissued Dec. 10, 2019 as U.S. Pat. No. 10,501,873; which is aContinuation Application of U.S. application Ser. No. 14/197,820, filedMar. 5, 2014, entitled “Moisture Management Support Garment With ADenier Differential Mechanism,” and issued Jun. 13, 2017 as U.S. Pat.No. 9,677,207; which is a Divisional Application of U.S. applicationSer. No. 12/987,235, filed Jan. 10, 2011, entitled “Moisture ManagementSupport Garment With A Denier Differential Mechanism,” and issued Apr.22, 2014 as U.S. Pat. No. 8,702,469. Each of these is incorporated byreference in its entirety.

FIELD

The present disclosure relates to moisture management apparel for wearduring exertion.

BACKGROUND

Sweat evaporation from a person's skin is one of the most importantcooling mechanisms during exertion. Typically, in a given set ofenvironmental conditions, a person will perspire at an increased ratewith increasing exertion. Perspiration rate may be exacerbated by thefact that skin temperatures become progressively warmer with tighterfitting garments. Sweat saturated garments are not only uncomfortable tothe wearer but can promote bacterial proliferation and adversely affectthermal regulation. Moisture management is the ability of a fabric totransport sweat away from the body in order to keep the wearer dry andcomfortable.

SUMMARY

Accordingly, despite the improvements of known athletic garments, manyapproaches to moisture management rely upon material properties oftextiles. A denier differential mechanism is presented herein, utilizingmorphological properties of fibers and textiles, to provide moisturemanagement properties. Denier differential refers to yarn of differentdenier or thickness on the face versus the back of a textile. A moisturemanagement fabric may be engineered with two sides: a facing layer and aback layer. Surface tension and capillary forces drive the moisture fromthe wearer's skin to the back layer. Moisture then moves from the backlayer to the facing layer due to increased surface area of the facinglayer. Due to the increased surface area of the facing layer, moisturemay be spread out with greater surface area to evaporate.

One example includes a moisture management support garment comprising afirst fabric layer comprising a first yarn of a first denier perfilament, wherein the first denier per filament is between 0.50 and1.04, and a second fabric layer adjacent the first fabric layercomprising a second yarn of a second denier per filament greater thanthe first denier per filament, wherein the second denier per filament isbetween 1.04 and 3.50 and a denier differential between the first denierper filament and the second denier per filament is at least 0.54,wherein the second fabric layer is the inner most layer of the garmentwhen the garment is worn. Additionally, the first yarn may be polyesterand the second yarn may be polyester. In another example, the first yarnmay be nylon and the second yarn may be polyester. The first fabriclayer may be single-knit and the second fabric layer may also besingle-knit. Alternatively, the first fabric layer and the second fabriclayer are double-knit. In another example, the first fabric layer andthe second fabric layer are plaited single-knit. Furthermore, themoisture management support garment may comprise a third fabric layer ofa third yarn of a third denier per filament, wherein the third denierper filament is between 0.50 and 1.04 and the third fabric layer isdisposed between the first fabric layer and the second fabric layer. Themoisture management support garment may comprise a fourth fabric layerof a fourth yarn of a fourth denier per filament, wherein the fourthdenier per filament is between 1.04 and 3.5 and the fourth fabric layeris disposed between the third fabric layer and the second fabric layer.In another example, the moisture management support ferment may comprisea fifth fabric layer of a fifth yarn of a fifth denier per filament,wherein the fifth denier per filament is between 1.04 and 3.5, whereinthe fifth fabric layer is disposed between the first fabric layer andthe second fabric layer. For example, the fifth denier per filament maybe greater than the first denier per filament but less than or equal tothe second denier per filament. Additional layers may have a denier perfilament between the first denier per filament and the second denier perfilament forming a denier per filament gradient. In another example, thefirst fabric layer may have a stretch of at least 30% and the secondfabric layer may have a stretch of at least 30%.

An additional example includes a moisture management fabric comprising afirst fabric layer comprising a first yarn of a first denier perfilament, wherein the first denier per filament is less than or equal to1.04, and a second fabric layer adjacent to the first fabric layercomprising a second yarn of a second denier per filament greater thanthe first denier per filament, wherein the second denier per filament isgreater than or equal to 1.04 and a denier differential between thefirst denier per filament and the second denier per filament is at least0.54. Furthermore, the first yarn may be polyester and the second yarnmay be polyester. In one example, the first yarn may be nylon and thesecond yarn may be polyester. The first fabric layer may be single-knitand the second fabric layer may be single-knit. In another example, thefirst fabric layer and the second fabric layer may be either double-knitor plaited single-knit. Additionally, the first fabric layer may have astretch of at least 30%. The second fabric layer may also have a stretchof at least 30%. The moisture management fabric may further comprise atleast one additional fabric layer of a third yarn of a third denier perfilament, wherein the at least one additional fabric layer is disposedbetween the first fabric layer and the second fabric layer. Additionallayers may have a denier per filament between the first denier perfilament and the second denier per filament forming a denier perfilament gradient. In one example, the third denier per filament is lessthan or equal to 1.04. In another example, the third denier per filamentis greater than 1.04. The moisture management fabric may furthercomprise at least one additional fabric layer of a fourth yarn of afourth denier per filament, wherein the fourth denier per filament isgreater than or equal to 1.04. The moisture management fabric mayfurther comprise at least one additional fabric layer of a fourth yarnof a fourth denier per filament, wherein the fourth denier per filamentis less than or equal to 1.04.

Another example includes a moisture transporting sport bra comprising afacing layer, the facing layer comprising a first yarn of a first denierper filament, wherein the first denier per filament is between 0.50 and1.04; and a back layer adjacent the facing layer, the back layercomprising a second yarn of a second denier per filament greater thanthe first denier per filament, wherein the second denier per filament isbetween 1.04 and 3.50 and a denier differential between the first denierper filament and the second denier per filament is at least 0.54,wherein the back layer is adjacent to the skin of a wearer when themoisture transporting sport bra is worn. In one example, the first yarnmay be polyester and the second yarn may be polyester. In anotherexample, the first yarn may be nylon and the second yarn may bepolyester. Furthermore, the facing layer may be single-knit and the backlayer may be single-knit. The facing layer and the back layer may bedouble-knit or plaited single knit. The moisture transporting sport bramay comprise a third fabric layer of a third yarn of a third denier perfilament, wherein the third fabric layer is disposed between the facinglayer and the back layer. Additional layers may have a denier perfilament between the first denier per filament and the second denier perfilament forming a denier per filament gradient. The third denier perfilament may be less than or equal to 1.04. In another example, thethird denier per filament may be greater than or equal to 1.04. Forexample, the third denier per filament may be greater than the firstdenier per filament but less than or equal to the second denier perfilament. The third fabric layer and the facing layer may be double-knitand the back layer may be single-knit. The third fabric layer and theback layer are double-knit and the facing layer is single-knit. Themoisture transporting sport bra may further comprise a fourth fabriclayer of a fourth yarn of a fourth denier per filament, wherein thefourth denier per filament may be less than or equal to 1.04 and thefourth fabric layer may be disposed between the facing layer and thethird fabric layer.

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected examples and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIGS. 1A-D are schematics of an exemplary denier differential fabricwith an illustrative moisture path from the wearer's body surface to theexterior of the fabric and exemplary denier differential fabrics withone or more additional fabric layers.

FIGS. 2A-B are illustrations of aspects of the yarns comprising a denierdifferential fabric.

FIG. 3 is an illustration of an exemplary moisture management supportgarment.

FIGS. 4A-B are schematics of an exemplary knitted fabric layer and anexemplary knitted fabric layer which may comprise a denier differentialfabric.

FIGS. 5A-B are schematics of an exemplary woven fabric layer and anexemplary woven fabric layer which may comprise a denier differentialfabric.

FIGS. 6A-D are schematics of an exemplary moisture management supportgarment with an illustrative moisture path from the wearer's bodysurface to the exterior of the garment and further exemplary moisturemanagement support garments including additional fabric layers.

FIG. 7 is an illustration of an exemplary moisture transporting sportbra.

FIG. 8A-D are schematics of an exemplary moisture transporting sport brawith an illustrative moisture path from the wearer's body surface to theexterior of the sport bra and exemplary moisture transporting sport braswith additional fabric layers.

FIGS. 9A-B are illustrations of exemplary stretchable denierdifferential fabric.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Referring to FIG. 1A, an example of a moisture management fabric isdepicted. The moisture management fabric 101 comprises two layers: afirst fabric layer 103 and a second fabric layer 102. Additional aspectsmay include additional layers adjacent first or second fabric layer orboth that may provide tailored levels of moisture management and supportin a composite fabric. Both the first fabric layer 103 and second fabriclayer 102 may be constructed of a yarn or thread.

The first fabric layer 103 and the second fabric layer 102 may beconstructed separately, by knitting or weaving, and assembled to formthe fabric. In another example, the layer 103 and the second fabriclayer 102 may be constructed continuously, by knitting or weaving, toform a seamless fabric. The second fabric layer 102 is the layeradjacent to the wearer's body 100 and the first fabric layer 103 isadjacent to the second fabric layer 102. The wearer's body 100 perspiresand moisture may be adsorbed 104 from the body 100 surface to the firstfabric layer 103. The denier differential, which is discussed in greaterdetail below, between the first fabric layer 103 and the second fabriclayer 102, can provide a difference in porosity and surface area whereinthe first fabric layer 103 has a greater surface area and smaller poresthan the second fabric layer 102. The smaller pores and greater surfacearea results in increased capillary force for aqueous solutions for thefirst fabric layer 103 than the second fabric layer 102. The denierdifferential produces wicking 105 from the second fabric layer 102 tothe first fabric layer 103. The moisture, once transported to the firstfabric layer 103, may be adsorbed to and spread out over the increasedsurface area of the first fabric layer 103. The increased surface areaof the first fabric layer 103 can encourage moisture evaporation 106from the first fabric layer 103. The moisture management fabric can thustransport moisture efficiently from the wearer 100, to the second fabriclayer 102 to keep the wearer comfortable, and to the first fabric layer103 to promote evaporation from the fabric to keep the wearer dry.

FIGS. 1B-D illustrate examples of a moisture management fabric with atleast one additional fabric layer. FIG. 1B illustrates a third fabriclayer 109 disposed between the first fabric layer 110 and the secondfabric layer 108. In this example of a moisture management fabric, thethird fabric layer 109 may be constructed by knitting or weaving a thirdyarn or thread. The first fabric layer may be constructed by knitting orweaving a first yarn and the second fabric layer may be constructed byknitting or weaving a second yarn. In FIG. 1B, the third fabric layer109 may be constructed such that the porosity and surface area of thethird fabric layer 109 is greater than the porosity and surface area ofthe second fabric layer 108. The third fabric layer 109 may beconstructed by knitting or weaving third yarn of a third denier perfilament, which is comparable in size to or larger than the first yarn.The denier per filament of the third fabric layer 109 may be greaterthan the denier per filament of the first fabric layer 110 and less thanthe denier per filament of the second fabric layer 108 such that agradient of surface areas and porosities is provided. The first fabriclayer and the third fabric layer may be knitted separately, double-knit,or plaited single-knit. The second fabric layer may be knittedseparately. In another example, the third fabric layer and the secondfabric layer may be knitted separately, double knit, or plaited singleknit. The first fabric layer may be knitted separately.

FIG. 1C illustrates a moisture management fabric 116 having at least athird fabric layer 114 which is an intermediate layer of the fabricdisposed between the first fabric layer 115 and the second fabric layer113. In one example of a moisture management fabric 116, the thirdfabric layer 114 may be constructed by knitting or weaving a third yarnor thread. The first fabric layer 115 may be constructed by knitting orweaving a first yarn or thread; and the second fabric layer 113 may beconstructed by knitting or weaving a second yarn or thread. In FIG. 1C,the third fabric layer 114 may be constructed such that the porosity andsurface area of the third fabric layer 114 is less than the porosity andsurface area of the first fabric layer 115. The third fabric layer 114may be constructed by knitting or weaving a yarn or thread, which iscomparable in size to or less than in size than yarn or thread of thesecond fabric layer 113. The denier per filament of the third fabriclayer 114 may be greater than the denier per filament of the firstfabric layer 115 and less than the denier per filament of the secondfabric layer 113 such that a gradient of surface areas and porosities isprovided. The first fabric layer 115 and the third fabric layer 114 maybe knitted separately, double-knit, or plaited single-knit. The secondfabric layer 113 may be knitted separately. In another example, thethird fabric layer 114 and the second fabric layer 113 may be knittedseparately, double knit, or plaited single knit. The first fabric layer115 may be knitted separately.

FIG. 1D illustrates moisture management fabric 122 having at least athird fabric layer 120 and a fourth fabric layer 119 each of which is anintermediate layer of the fabric disposed between the first fabric layer121 and the second fabric layer 118. In one example of a moisturemanagement fabric, the third fabric layer 120 may be constructed byknitting or weaving a third yarn or thread. In one example of a moisturemanagement fabric, the fourth fabric layer 119 may be constructed byknitting or weaving a third yarn or thread. The first fabric layer 121may be constructed by knitting or weaving a first yarn or thread; andthe second fabric layer 118 may be constructed by knitting or weaving asecond yarn or thread. In FIG. 1D, the fabric 122 may be constructedsuch that the porosity and surface area of the third fabric layer 120 isless than the porosity and surface area of the first fabric layer 121and the porosity and surface area of the fourth fabric layer 119 isgreater than the porosity and surface area of the second fabric layer.In one example, the third fabric layer 120 has a porosity and surfacearea between that of the fourth fabric layer 119 and the first fabriclayer 121; and the fourth fabric layer 119 has a porosity and surfacearea between that of the third fabric layer 120 and the second fabriclayer. The first fabric layer 121, the second fabric layer 118, thethird fabric layer 120, and the fourth fabric layer 119 may be woven orknitted separately. Alternatively, adjacent layers, such as the firstfabric layer 121 and the third fabric layer 120, the third fabric layer120 and the fourth fabric layer 119, the fourth fabric layer 119 and thesecond fabric layer 118 may be double-knit or plaited single-knit andcombined with the remaining single, double-knit, or plaited single-knitlayers.

Any combination of the examples illustrated in FIGS. 1A-D may beemployed to achieve a moisture management fabric. Examples including aplurality of fabric layers may provide a gradient of surface areas andporosities for a composite fabric. In another example, additional fabriclayers adjacent to the first fabric layer and second fabric layer mayhave similar porosity and surface area as the contacting first fabriclayer and second fabric layer. In another example, a plurality of theabove described fabric layers may provide a moisture management fabricwith specific moisture management properties.

FIGS. 2A-B illustrate examples of the yarns that may be employed in theconstruction of the denier differential fabric. The yarns depicted inFIGS. 2A-B are not to scale and furthermore not limiting to yarns orfibers used in accordance with the invention. FIG. 2A illustrates anexemplary second yarn 201 that may be used to construct a moisturemanagement support garment. The yarn may be a monofilament ormultifilament yarn of any known synthetic or natural fiber. The yarn maybe a filament yarn or a spun yarn. The exemplary second yarn 201 may bea bundle 203 of individual filaments 202. The total yarn size 204 may bemeasured in denier, for example 9,000 m of the exemplary yarn weighs X ghas a size of X denier. The denier per filament is calculated bydividing the total yarn size (X denier) by the total number 200 offilaments 202. In FIG. 2B, an exemplary first yarn 206 may be used toconstruct a moisture management support garment. The exemplary firstyarn 206 may be a bundle 209 of individual filaments 208 of any knownsynthetic or natural fiber. The exemplary first yarn 206 may have a size207 represented as Y denier, for a first yarn 206 weighing Y g for 9,000m. The denier per filament is calculated by dividing the total yarn size(Y denier) by the total number 205 of filaments 208. A yarn of less thanor equal to 1.04 denier per filament may be a microfiber. The denierdifferential may be described as the difference in the denier perfilament of the first yarn and the denier per filament of the secondyarn. The first yarn 206 may be composed of nylon or polyester and thesecond yarn 201 may be composed of polyester. Moreover, surfacetreatment or additional modification may be employed to impart a greaterrelative hydrophobicity to the macrofiber or a great relativehydrophillicity to the microfiber. Not shown are third and fourth yarnswhich may also be a bundle of individual filaments or any knownsynthetic or natural fiber. Third and fourth yarns may also be measuredin terms of a third and fourth denier per filament, respectively.

In one example, the first fabric layer may be knitted or woven of afirst yarn of a first denier per filament of less than or equal to 1.04denier per filament, preferably 0.50 to 1.04 denier per filament. Thesecond fabric layer may be knitted or woven of a second yarn of a seconddenier per filament of greater than or equal to 1.04 denier perfilament, preferably 1.04 to 3.50. The denier differential between thefirst yarn and the second yarn may be at least 0.54. The third fabriclayer may be knitted or woven of a third yarn of a third denier perfilament. In one example, the third denier per filament is less than orequal to 1.04 denier per filament, preferably 0.50 to 1.04 denier perfilament. In another example, the third denier per filament is greaterthan or equal to 1.04, preferably 1.04 to 3.50. The third denier perfilament may be a value less than the second denier per filament butgreater than the first denier per filament. In another example, thefourth fabric layer may be knitted or woven of a fourth yarn of a fourthdenier per filament. The fourth denier per filament may be less than orequal to 1.04 denier per filament, preferably 0.50 to 1.04 denier perfilament. Alternatively, the fourth denier per filament may be greaterthan or equal to 1.04, preferably 1.04 to 3.50. The fourth denier perfilament may be a value less than the second denier per filament butgreater than the first denier per filament.

Referring to FIG. 3, one example of a moisture management supportgarment 301 is illustrated. The moisture management fabric describedpreviously may be used to construct any number of garments that aresuitable for the applications of the wearer 300. The moisture managementsupport garment 301 provides improved sweat wicking and evaporationduring exertion. The moisture management support garment 301 may beconstructed using any garment manufacturing means. Additionally, themoisture management support garment 301, while incorporating the denierdifferential mechanism, may employ other fabrics and materials to modifythe performance parameters. For example, the moisture management supportgarment 301 may incorporate a plurality of fabric layers that employthat denier differential mechanism to form a composite garment that canhave moisture management properties tailored to specific applicationssuch as various sports or levels of exertion.

Referring to FIGS. 4A-B, one example of a first fabric layer 400 andsecond fabric layer 403 of an exemplary knitted moisture managementsupport garment is illustrated. FIG. 4A depicts an exemplary knittedstructure of the first yarn 401 to form a first knit 400 with relativelysmall pores 402 and high porosity. FIG. 4B also depicts an exemplaryknitted structure of the corresponding second yarn 404 to form thesecond knit 403 with fewer pores 405 of greater size and lower porosity.The knits depicted in FIGS. 4A-B are not to scale and furthermore notlimiting to the knitted structure of the fabric used in accordance withthe present invention, for which any pattern or method of knitting maybe employed. The first knit 400 and the second knit 403 may be singleknit separately and joined to form the exemplary fabric. In one example,the first knit 400 and the second knit 403 may be a double-knit.Alternatively, the first knit 400 and the second knit 403 may be aplaited single knit.

Referring to FIGS. 5A-B, one example of a first fabric layer 500 andsecond fabric layer 503 of an exemplary woven moisture managementsupport garment is illustrated. FIG. 5A depicts an exemplary wovenstructure of the first yarn 501 to form a first weave 500 withrelatively small pores 502 and high porosity. FIG. 5B also depicts anexemplary woven structure of the corresponding second yarn 504 to formthe second weave 503 with fewer pores 505 of greater size and lowerporosity. The woven structures depicted in FIGS. 5A-B are not to scaleand furthermore not limiting to the woven structure of the fabric usedin accordance with the present invention, for which any pattern ormethod of weaving may be employed.

FIG. 6A-6D an example of a moisture management support garment isdepicted. The moisture management support garment 601 comprises twolayers: a first fabric layer 603 and a second fabric layer 602.Additional examples may include additional layers adjacent first orsecond fabric layer or both that may provide tailored levels of moisturemanagement and support in a composite fabric. Both the first fabriclayer 603 and second fabric layer 602 may be constructed of a yarn orthread. The first fabric layer 603 may be constructed of a first yarnhaving a denier per filament of less than or equal to 1.04. The secondfabric layer 602 may be constructed of a second yarn or thread ofgreater than or equal to 1.04. The denier differential between the firstyarn and the second yarn may be at least 0.54.

The first fabric layer 603 and the second fabric layer 602 may beconstructed separately, by knitting or weaving, and assembled to formthe fabric. In another example, the layer 603 and the second fabriclayer 602 may be constructed continuously, by knitting or weaving, toform a seamless fabric. The second fabric layer 602 is the layeradjacent to the wearer's body 600 and the first fabric layer 603 isadjacent to the second fabric layer 602. The wearer's body 600 perspiresand moisture may be adsorbed 604 from the body 600 surface to the firstfabric layer 603. The denier differential between the first fabric layer603 and the second fabric layer 602, can provide a difference inporosity and surface area wherein the first fabric layer 603 has agreater surface area and smaller pores than the second fabric layer 602.The smaller pores and greater surface area results in increasedcapillary force for aqueous solutions for the first fabric layer 603than the second fabric layer 602. The denier differential produceswicking 605 from the second fabric layer 602 to the first fabric layer603. The moisture, once transported to the first fabric layer 603, maybe adsorbed to and spread out over the increased surface area of thefirst fabric layer 603. The increased surface area of the first fabriclayer 603 can encourage moisture evaporation 606 from the first fabriclayer 603. The moisture management support garment 601, which may beconstructed of a moisture management fabric described above, can thustransport moisture efficiently from the wearer 600, to the second fabriclayer 602 to keep the wearer comfortable, and to the first fabric layer603 to promote evaporation from the garment to keep the wearer dry.

FIGS. 6B-D illustrate examples of moisture management support garmentwith at least one additional fabric layer. FIG. 6B illustrates amoisture management support garment 611 having at least a third fabriclayer 609 disposed between the first fabric layer 610 and the secondfabric layer 608. In this example of a moisture management supportgarment, the third fabric layer 609 may be constructed by knitting orweaving a third yarn or thread. The first fabric layer may beconstructed by knitting or weaving a first yarn and the second fabriclayer may be constructed by knitting or weaving a second yarn.

In FIG. 6B, the third fabric layer 609 may be constructed such that theporosity and surface area of the third fabric layer 609 is greater thanthe porosity and surface area of the second fabric layer 608. The thirdfabric layer 609 may be constructed by knitting or weaving third yarn ofa third denier per filament, which is comparable in size to or largerthan the first yarn. The third fabric layer 609 may be constructed of ayarn having a denier per filament of less than or equal to 1.04. Forexample, the denier per filament of the third fabric layer may begreater than the denier per filament of the first fabric layer 610 butless than the denier per filament of the second fabric layer 608 therebyforming a gradient of surface areas and porosities. The first fabriclayer and the third fabric layer may be knitted separately, double-knit,or plaited single-knit. The second fabric layer may be knittedseparately. In another example, the third fabric layer and the secondfabric layer may be knitted separately, double knit, or plaited singleknit. The first fabric layer may be knitted separately.

FIG. 6C illustrates a moisture management support garment 616 having atleast a third fabric layer 614 which is an intermediate layer of thegarment disposed between the first fabric layer 615 and the secondfabric layer 613. In one example of a moisture management supportgarment 616, the third fabric layer 614 may be constructed by knittingor weaving a third yarn or thread. The third fabric layer 614 may beconstructed of a third yarn having a denier per filament of greater thanor equal to 1.04. The first fabric layer 615 may be constructed byknitting or weaving a first yarn or thread; and the second fabric layer613 may be constructed by knitting or weaving a second yarn or thread.

In FIG. 6C, the third fabric layer 614 may be constructed such that theporosity and surface area of the third fabric layer 614 is less than theporosity and surface area of the first fabric layer 615. The thirdfabric layer 614 may be constructed by knitting or weaving a yarn orthread, which is comparable or smaller in size to yarn or thread of thesecond fabric layer 613. For example, the denier per filament of thethird fabric layer 614 may be greater than the denier per filament ofthe first fabric layer 615 but less than the denier per filament of thesecond fabric layer 613 thereby forming a gradient of surface areas andporosities. The first fabric layer 615 and the third fabric layer 614may be knitted separately, double-knit, or plaited single-knit. Thesecond fabric layer 613 may be knitted separately. In another example,the third fabric layer 614 and the second fabric layer 613 may beknitted separately, double knit, or plaited single knit. The firstfabric layer 615 may be knitted separately.

FIG. 6D illustrates a moisture management support garment 622 having atleast a third fabric layer 620 and a fourth fabric layer 619, each ofwhich is an intermediate layer of the garment disposed between the firstfabric layer 621 and the second fabric layer 618. In one example of amoisture management support garment 622, the third fabric layer 620 maybe constructed by knitting or weaving a third yarn or thread. In oneexample of a moisture management support garment 622, the fourth fabriclayer 619 may be constructed by knitting or weaving a third yarn orthread. The first fabric layer 621 may be constructed by knitting orweaving a first yarn or thread; and the second fabric layer 618 may beconstructed by knitting or weaving a second yarn or thread.

In FIG. 6D, the moisture management support garment 622 may beconstructed such that the porosity and surface area of the third fabriclayer 620 is less than the porosity and surface area of the first fabriclayer 621 and the porosity and surface area of the fourth fabric layer619 is greater than the porosity and surface area of the second fabriclayer. In one example, the third fabric layer 620 is constructed of ayarn having a denier per filament of less than or equal to 1.04 and thefourth fabric layer 619 is constructed of a yarn having a denier perfilament of greater than or equal to 1.04. In one example, the thirdfabric layer 620 has a porosity and surface area between that of thefourth fabric layer 619 and the first fabric layer 621; and the fourthfabric layer 619 has a porosity and surface area between that of thethird fabric layer 620 and the second fabric layer. The first fabriclayer 621, the second fabric layer 618, the third fabric layer 620, andthe fourth fabric layer 619 may be woven or knitted separately.Alternatively, adjacent layers, such as the first fabric layer 621 andthe third fabric layer 620, the third fabric layer 620 and the fourthfabric layer 619, the fourth fabric layer 619 and the second fabriclayer 618 may be double-knit or plaited single-knit and combined withthe remaining single, double-knit, or plaited single-knit layers.

Any combination of the examples illustrated in FIGS. 6A-D may beemployed to achieve a moisture management support garment. Examplesincluding a plurality of fabric layers may provide a gradient of surfaceareas and porosities for a composite garment. In another example,additional fabric layers adjacent to the first fabric layer and secondfabric layer may have similar porosity and surface area as thecontacting first fabric layer and second fabric layer. In anotherexample, a plurality of the above described fabric layers may provide agarment of specific moisture management properties.

FIG. 7 is an instance wherein the moisture management support garmentmay be a moisture transporting sport bra 701 worn close to andconformally by the wearer 700. The moisture transporting sport bra 701provides mechanical support to the wearer while allowing improved sweatwicking and evaporation during exertion. The moisture transporting sportbra 701 may be constructed using any garment manufacturing means.Additionally, the moisture transporting sport bra 701, whileincorporating the denier differential mechanism, may employ otherfabrics and materials to modify the performance parameters. For example,the moisture transporting sport bra 701 may incorporate a plurality offabric layers that employ that denier differential mechanism to form acomposite sport bra that can have moisture management propertiestailored to specific applications such as various sports or levels ofexertion.

FIG. 8A-8D illustrate examples of a moisture transporting sport bra. Themoisture transporting sport bra may be constructed of the moisturetransporting fabric described above. The moisture transporting sport bra801 comprises two layers: a facing layer 803 and a back layer 802.Additional examples may include additional layers adjacent facing orback layer or both that may provide tailored levels of moisturemanagement and support in a composite fabric. Both the facing layer 803and back layer 802 may be constructed of a yarn or thread. The facinglayer 803 may be constructed of a first yarn having a denier perfilament of less than or equal to 1.04, preferably between 0.50 and 1.04denier per filament. The back layer 802 may be constructed of a secondyarn or thread of greater than or equal to 1.04, preferably between 1.04and 3.50 denier per filament. The denier differential between the firstyarn and the second yarn may be at least 0.54.

The facing layer 803 and the back layer 802 may be constructedseparately, by knitting or weaving, and assembled to form the fabric. Inanother example, the facing layer 803 and the back layer 802 may beconstructed continuously, by knitting or weaving, to form a seamlessfabric. The back layer 802 is the layer adjacent to the wearer's body800 and the facing layer 803 is adjacent to the back layer 802. Thewearer's body 800 perspires and moisture may be adsorbed 804 from thebody 800 surface to the facing layer 803. The denier differentialbetween the facing layer 803 and the back layer 802 can provide adifference in porosity and surface area wherein the facing layer 803 hasa greater surface area and smaller pores than the back layer 802. Thesmaller pores and greater surface area results in increased capillaryforce for aqueous solutions for the facing layer 803 than the back layer802. The denier differential produces wicking 805 from the back layer802 to the facing layer 803. The moisture, once transported to thefacing layer 803, may be adsorbed to and spread out over the increasedsurface area of the facing layer 803. The increased surface area of thefacing layer 803 can encourage moisture evaporation 808 from the facinglayer 803. The moisture transporting sport bra 801, which may beconstructed of a moisture management fabric described above, can thustransport moisture efficiently from the wearer 800, to the back layer802 to keep the wearer comfortable, and to the facing layer 803 topromote evaporation from the moisture management sport bra to keep thewearer dry.

FIGS. 8B-D illustrate examples of moisture transporting sport bra withat least one additional fabric layer. FIG. 8B illustrates a moisturetransporting sport bra 811 having at least a third fabric layer 109disposed between the facing layer 810 and the back layer 808. In thisexample of a moisture transporting sport bra, the third fabric layer 809may be constructed by knitting or weaving a third yarn or thread. Thefacing layer may be constructed by knitting or weaving a first yarn andthe back layer may be constructed by knitting or weaving a second yarn.

In FIG. 8B, the third fabric layer 809 may be constructed such that theporosity and surface area of the third fabric layer 809 is greater thanthe porosity and surface area of the back layer 808. The third fabriclayer 809 may be constructed by knitting or weaving third yarn of athird denier per filament, which is comparable in size to the firstyarn. The third fabric layer 809 may be constructed of a yarn having adenier per filament or less than or equal to 1.04. The facing layer andthe third fabric layer may be knitted separately, double-knit, orplaited single-knit. The back layer may be knitted separately. Inanother example, the third fabric layer and the back layer may beknitted separately, double knit, or plaited single knit. The facinglayer may be knitted separately.

FIG. 8C illustrates a moisture transporting sport bra 818 having atleast a third fabric layer 814 which is an intermediate layer of themoisture management sport bra disposed between the facing layer 815 andthe back layer 813. In one example of a moisture transporting sport bra818, the third fabric layer 814 may be constructed by knitting orweaving a third yarn or thread. The third fabric layer 814 may beconstructed of a third yarn having a denier per filament of greater thanor equal to 1.04. The facing layer 815 may be constructed by knitting orweaving a first yarn or thread; and the back layer 813 may beconstructed by knitting or weaving a second yarn or thread.

In FIG. 8C, the third fabric layer 814 may be constructed such that theporosity and surface area of the third fabric layer 814 is less than theporosity and surface area of the facing layer 815. The third fabriclayer 814 may be constructed by knitting or weaving a yarn or thread,which is comparable in size to yarn or thread of the back layer 813. Thefacing layer 815 and the third fabric layer 814 may be knittedseparately, double-knit, or plaited single-knit. The back layer 813 maybe knitted separately. In another example, the third fabric layer 814and the back layer 813 may be knitted separately, double knit, orplaited single knit. The facing layer 815 may be knitted separately.

FIG. 8D illustrates a moisture transporting sport bra 822 having atleast a third fabric layer 820 and a fourth fabric layer 819, each ofwhich is an intermediate layer of the moisture management sport bradisposed between the facing layer 821 and the back layer 818. In oneexample of a moisture transporting sport bra 822, the third fabric layer820 may be constructed by knitting or weaving a third yarn or thread. Inone example of a moisture transporting sport bra 822, the fourth fabriclayer 819 may be constructed by knitting or weaving a third yarn orthread. The facing layer 821 may be constructed by knitting or weaving afirst yarn or thread; and the back layer 818 may be constructed byknitting or weaving a second yarn or thread.

In FIG. 8D, the moisture transporting sport bra 822 may be constructedsuch that the porosity and surface area of the third fabric layer 820 isequal to or less than the porosity and surface area of the facing layer821 and the porosity and surface area of the fourth fabric layer 819 isgreater than or equal to the porosity and surface area of the backlayer. The sport bra 822 to may constructed such that a gradient ofsurface area from greatest to smallest goes from facing layer 821 toback layer 818 with intermediate layers having intermediate andgraduated surface areas. Additional layers inserted between the facinglayer 821 and the back layer 818 may provide a gradient of surface areaand porosity. In one example, the third fabric layer 820 is constructedof a yarn having a denier per filament of less than or equal to 1.04 andthe fourth fabric layer 819 is constructed of a yarn having a denier perfilament of greater than or equal to 1.04. In one example, the thirdfabric layer 820 has a porosity and surface area between that of thefourth fabric layer 819 and the facing layer 821; and the fourth fabriclayer 819 has a porosity and surface area between that of the thirdfabric layer 820 and the back layer. The facing layer 821, the backlayer 818, the third fabric layer 820, and the fourth fabric layer 819may be woven or knitted separately. Alternatively, adjacent layers, suchas the facing layer 821 and the third fabric layer 820, the third fabriclayer 820 and the fourth fabric layer 819, the fourth fabric layer 819and the back layer 818 may be double-knit or plaited single-knit andcombined with the remaining single, double-knit, or plaited single-knitlayers.

Any combination of the examples illustrated in FIGS. 8A-D may beemployed to achieve a moisture transporting sport bra. Examplesincluding a plurality of fabric layers may provide a gradient of surfaceareas and porosities for a composite moisture management sport bra. Inanother example, additional fabric layers adjacent to the facing layerand back layer may have similar porosity and surface area as thecontacting facing layer and back layer. In another example, a pluralityof the above described fabric layers may provide a moisture managementsport bra of specific moisture management properties.

FIGS. 9A-B are schematics of aspects of the moisture management supportgarment wherein at least a portion of the garment can have a stretch ofat least 30%, preferably 30% to 50%. Stretch may be imparted to agarment by knitting to produce an inherent stretch or by including aportion of stretchable material such as Spandex. Portions of anexemplary moisture management support garment may include regions ofdifferent stretch and rigidity to provide additional support. In anotherexample, at least a portion of the moisture transporting sport bra canhave a stretch of at least 30%, preferably 30% to 50%. The moisturetransporting sports bra may include “locked out” areas such as the cup,shoulder strap, center-front, and wings that have different degrees ofstretch in order to provide suitable support. In another example, atleast a portion of the facing layer may have a stretch of at least 30%,preferably 30% to 50%. At least a portion of the corresponding backlayer may have a stretch of at least 30%, preferably 30% to 50%.Examples may also include a facing layer and corresponding back layerwith reduced or increased stretch to provide suitable support forvarious garment applications. Exemplary stretch may be achieved byknitting or employing elastic fibers. In an additional example, thefacing layer may have a stretch of at least 30%, preferably 30% to 50%.The corresponding back layer may have a stretch of at least 30%,preferably 30% to 50%. Examples may also include a facing layer and abacking layer with regions of different stretch to provide suitablesupport for any garment application. As shown in FIG. 9A, portions ofthe facing layer or first layer 901 may stretch omni-directionally 902and portions of the back layer or second layer 903 may stretchomni-directionally. As shown in FIG. 9B, portions of the facing layer orfirst layer 905 may stretch uni-axially 906 and portions of the backlayer or second layer 907 may stretch uni-axially. A garment or fabriccontaining a plurality of layers disposed between the facing layer andback layer may have complementary or coordinating stretch imparted tothe plurality of layers. Composite moisture management fabric andmoisture management support garments may have layers of variablestretchability to tailor performance and fit of the product. Additionalaspects may include any plurality of directional stretching in differentregions of the garment and/or textile to provide suitable support forany garment application.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the invention. Individual elements or features ofa particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and may be usedin a selected embodiment, even if not specifically shown or described.

What is claimed is:
 1. A moisture management fabric used to form agarment, the moisture management fabric comprising: a first fabric layercomprising a first yarn having a first denier per filament; a secondfabric layer configured to face a body surface when formed into thegarment, the second fabric layer comprising a second yarn having asecond denier per filament that is greater than the first denier perfilament, wherein a denier per filament differential between the firstdenier per filament and the second denier per filament is at least 0.54;and a third fabric layer comprising a third yarn having a third denierper filament, wherein the third fabric layer is disposed between thefirst fabric layer and the second fabric layer.
 2. The moisturemanagement fabric of claim 1, wherein a denier per filament gradient isformed between the second fabric layer, the third fabric layer, and thefirst fabric layer.
 3. The moisture management fabric of claim 1,wherein the second denier per filament is greater than the third denierper filament and the third denier per filament is greater than the firstdenier per filament.
 4. The moisture management fabric of claim 1,wherein the third denier per filament is the same as the second denierper filament.
 5. The moisture management fabric of claim 1, wherein thethird denier per filament is the same as the first denier per filament.6. The moisture management fabric of claim 1, wherein the first fabriclayer, the second fabric layer, and the third fabric layer have aporosity and a surface area, the first fabric layer porosity and surfacearea being greater than the third fabric layer porosity and surfacearea, and the third fabric layer porosity and surface area being greaterthan the second fabric layer porosity and surface area.
 7. The moisturemanagement fabric of claim 1, wherein the first yarn, the second yarn,or the third yarn is polyester or nylon.
 8. The moisture managementfabric of claim 1, wherein at least one of the first fabric layer, thesecond fabric layer, or the third fabric layer is knitted with elasticfibers.
 9. The moisture management fabric of claim 8, wherein theelastic fibers are knitted with the second yarn of the second fabriclayer that is configured to face the body surface, such that the secondfabric layer comprises a stretch of up to 50%.
 10. The moisturemanagement fabric of claim 9, wherein the stretch is 30% to 50%.
 11. Themoisture management fabric of claim 8, wherein the elastic fibers areknitted with the first yarn of the first fabric layer, such that thefirst fabric layer comprises a stretch of up to 50%.
 12. The moisturemanagement fabric of claim 11, wherein the stretch is 30% to 50%.
 13. Amoisture management fabric used to form a garment, the moisturemanagement fabric comprising: a first fabric layer comprising a firstyarn having a first denier per filament; a second fabric layerconfigured to face a body surface when formed into the garment, thesecond fabric layer comprising a second yarn having a second denier perfilament that is greater than the first denier per filament, wherein adenier per filament differential between the first denier per filamentand the second denier per filament is at least 0.54; a third fabriclayer comprising a third yarn having a third denier per filament,wherein the third fabric layer is disposed between the first fabriclayer and the second fabric layer; and a fourth fabric layer comprisinga fourth yarn having a fourth denier per filament, wherein the fourthfabric layer is disposed between the second fabric layer and the thirdfabric layer.
 14. The moisture management fabric of claim 13, wherein adenier per filament gradient is formed across the second fabric layer,the fourth fabric layer, the third fabric layer, and the first fabriclayer.
 15. The moisture management fabric of claim 13, wherein thesecond denier per filament is greater than the fourth denier perfilament, the fourth denier per filament is greater than the thirddenier per filament, and the third denier per filament is greater thanthe first denier per filament.
 16. The moisture management fabric ofclaim 13, wherein the first fabric layer, the second fabric layer, thethird fabric layer, and the fourth fabric layer have a porosity and asurface area, the first fabric layer porosity and surface area beinggreater than the third fabric layer porosity and surface area, the thirdfabric layer porosity and surface area being greater than the fourthfabric layer porosity and surface area, and the fourth fabric layerporosity and surface area being greater than the second fabric layerporosity and surface area.
 17. The moisture management fabric of claim13, wherein at least one of the first fabric layer, the second fabriclayer, the third fabric layer, or the fourth fabric layer is knittedwith elastic fibers.
 18. The moisture management fabric of claim 17,wherein the elastic fibers are knitted with the second yarn of thesecond fabric layer that is configured to face the body surface, suchthat the second fabric layer comprises a stretch of up to 50%.
 19. Themoisture management fabric of claim 17, wherein the elastic fibers areknitted with the first yarn of the first fabric layer, such that thefirst fabric layer comprises a stretch of up to 50%.
 20. The moisturemanagement fabric of claim 17, wherein the elastic fibers are knittedwith the third yarn of the third fabric layer or the fourth yarn of thefourth fabric layer.